Fuel Injector: Service and Repair

WARNING: Do not smoke while working on the fuel system. Keep open flames or sparks away from your work area. Be sure to relieve fuel pressure while the ignition switch is off.

NOTE: The radio may have a coded theft protection circuit. Be sure to get the customer's code number before disconnecting the battery. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.

1. Disconnect the battery negative cable from the battery negative terminal.
2. Remove the fuel fill cap.
3. Use a box end wrench on the 6 mm service bolt at the fuel rail, while holding the special banjo bolt with another wrench.
4. Place a rag or shop towel over the 6 mm service bolt.

Fuel Pressure Release and Test Port:

5. Slowly loosen the 6 mm service bolt one complete turn.

NOTE:
^ A fuel pressure gauge can be attached at the 6 mm service bolt hole.
^ Always replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened.
^ Replace all washers whenever the bolts are removed.

Fuel Injector and Fuel Rail Exploded View:

6. Disconnect the electrical connectors from the injectors.
7. Disconnect the vacuum hose and fuel return hose from the pressure regulator.

NOTE: Place a rag or shop towel over the hose and tube before disconnecting them.

8. Loosen the retainer nuts on the fuel pipe and harness holder.
9. Disconnect the fuel pipe.
10. Remove the injectors from the intake manifold.
11. Slide new cushion rings onto the injectors.
12. Coat new O-rings with clean engine oil and put them on the injectors.
13. Insert the injectors into the fuel pipe first.
14. Coat the new seal rings with clean engine oil and press them into the intake manifold.
15. Install the injectors and fuel pipe assembly into the manifold.

CAUTION: To prevent damage to the O-ring, install the injectors in the fuel pipe first. Then install them into the intake manifold.

Fuel Injector Installation:

16. Install and tighten the retainer nuts and the fuel line.
17. Connect the fuel hose to the fuel rail with new washers.
18. Connect the vacuum hose and the fuel return hose to the pressure regulator.
19. Install the electrical connectors onto the injectors.
20. Turn the ignition switch ON but do not operate the starter. After the fuel pump runs for approximately two seconds, the fuel pressure rises. Repeat this two or three times, then check for fuel leaks.